Sports boot buckle with segmented rack

ABSTRACT

A lever and rack-type fastener assembly for sports footwear includes a lever assembly having a hooking member that is movably between an open position and a closed position for securing the footwear about the user&#39;s foot or ankle. A conformable segmented rack assembly is configured to engage the hook member. The segmented rack assembly includes a flexible cable, and a plurality of rack segments that is fixedly attached to the cable, wherein the cable provides a hinged joint between adjacent rack segments. Each of the rack segments includes a plurality of teeth. In some embodiments, an attachment plate clamps the rack members to the cable, in other embodiments, the rack members are formed with a crimpable channel for fixing the rack members to the cable.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/480,290, filed Apr. 28, 2011, the entire disclosure of which ishereby incorporated by reference herein.

BACKGROUND

Sport boots, for example ski boots, typically include a closure orfastening system for securing a boot about a user's foot and leg. Sportboots, and especially snow sport boots, present particular challenges.For example, sport boots are often bulky and may include substantiallyrigid components that make entry and exit from the boots more difficult.Sport boots for skiing and snowboarding provide the interface betweenthe user and the gliding board. To promote the desired performancerequires a very secure attachment between the user and the boot; thiswill allow the user to exert and react to the many and changing forcesexperienced during skiing and snowboarding. A secure attachment mustalso be comfortable because the user may be active for long periods oftime. Additionally, a user may need to remove a boot while on themountain for various reasons. It is desirable that the fastening systembe simple and easy to use to permit and facilitate removing and puttingboots back on in snowy and uneven terrain. It is also not uncommon for auser to want to alter the adjustment of the boot, for example, totighten or loosen the boot while in the field.

A prior art lever and rack-type fastening system is disclosed in U.S.Pat. No. 7,603,795, to Pallatin, which is hereby incorporated byreference in its entirety. Another exemplary prior art lever andrack-type fastening system is disclosed in U.S. Pat. No. 5,983,531, toChaigne et al., which is also hereby incorporated by reference in itsentirety. In another exemplary fastener system disclosed in U.S. Pat.No. 8,096,065, to Marechal et al., which is hereby incorporated byreference in its entirety, the lever is provided with a rack and pinionmechanism so that the pivoting movement of the lever generates atranslational movement of the mechanism.

A disadvantage of the rack members of prior art fastening systems isthat the rigid rack members do not conform to the user's boot andtherefore may contact the boot only over a small area, and/or be fixedto the boot shell. For example, prior art rack members on ski boots aretypically fixed to one side of the boot opening. Such rigid rack memberswill either be flat or more typically may have a fixed curvature. As thefastening system is tightened, the rack member typically moves the bootflap laterally to the desired tightened position. The tightened positionmay be different for different users, or even different for the sameuser at different times, for example, to accommodate different skiingconditions or skiing styles. The optimal curvature will typically varydepending on the lateral position of the rack member. Prior art rigidrack members are not able to conform to the optimal curvature needs ofthe user. The rigid rack members can result in discomfort to the user,damage and/or accelerated wear to the boot, less effective closure ofthe boot, and the opportunity for snow and other debris to become lodgedbetween the rack member and the boot. Such prior art rigid racks aretypically short and may not provide the range of adjustability desired.Improvements to lever and rack-type fastening systems would bebeneficial to overcome deficiencies in prior art closure systems. Forexample, it would be beneficial to provide a rack-type fastener systemthat is conformable to better adjust to the contours of sports footwear.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features ofthe claimed subject matter, nor is it intended to be used as an aid indetermining the scope of the claimed subject matter.

A conformable lever and rack-type fastener assembly for sports footwear,for example, ski boots, provides a rack assembly formed from articulatedsegments, such that the curvature of the rack assembly can vary toconform to the shape of the footwear. The conformable rack assembly cantherefore be moved laterally to different locations and stillapproximately conform to the footwear, for example, when the useradjusts the tension in the assembly, or when a different user uses thefootwear.

The fastener assembly includes a lever assembly with a hook member,which may be a conventional lever assembly. The conformable rackassembly comprises a cable, preferably comprising two parallel cableportions, and a plurality of rack segments that are serially attached tothe cable, such that the cable provides a hinged connection betweenadjacent rack segments.

In an embodiment, the rack segments include a toothed portion with teeththat are sized and configured to engage the hook member. The toothedportion may include parallel channels on a base portion that are sizedto receive the cable. An attachment plate attaches to the toothedportion, to clamp the rack segment at a desired position on the cable.The attachment plate may include parallel channels that are aligned withthe channels on the toothed portion when assembled, such that the cableengages the parallel channels and is clamped therebetween.

In an embodiment, the toothed portion is formed with a rivet portionthat is sized to extend through an aperture provided in the attachmentplate, wherein the rivet portion fixes the attachment plate to thetoothed portion.

In an embodiment, the rack segments are unitarily formed and includeoppositely disposed channel portions that are sized to receive thecable, and are configured to be crimped to lock the rack segment to thecable.

In an embodiment, the rack segments are formed with proximal and distalends that are curved and nest to facilitate articulation betweenadjacent rack segments. The rack segments may further be assembled withnarrow gaps therebetween, to further facilitate articulation.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same become betterunderstood by reference to the following detailed description, whentaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a side view of a rack and lever fastening system for a sportsboot in accordance with the present invention;

FIG. 2 is an exploded view of the rack assembly of the fastening systemshown in FIG. 1;

FIG. 3 is a bottom view of the rack assembly of the fastening systemshown in FIG. 1; and

FIG. 4 is a cross section view of the rack assembly of the fasteningsystem shown in FIG. 1;

FIG. 5 is a side view of a second embodiment of a rack assembly for arack and lever fastening system in accordance with the presentinvention;

FIG. 6 is a perspective view of a proximal rack segment for the rackassembly shown in FIG. 5;

FIG. 7 is a perspective view of a distal rack segment for the rackassembly shown in FIG. 5;

FIG. 8 is a lower-side perspective view of a third embodiment of a rackassembly for a rack lever fastening system in accordance with thepresent invention;

FIG. 9 is a partially exploded perspective view of a proximal racksegment for the rack assembly shown in FIG. 8; and

FIG. 10 is a partially exploded view of a distal rack segment for therack assembly shown in FIG. 8.

DETAILED DESCRIPTION

Particular embodiments of a fastening system in accordance with thepresent invention will now be described with reference to the FIGURES,wherein like numbers indicate like parts. FIG. 1 is a side view of afastening system 100 suitable for sports footwear and the like, forexample, ski boots, in accordance with the present invention. Thefastening system 100 comprises a conventional lever assembly 90 and anarticulated or conformable segmented rack assembly 110. The leverassembly 90 and segmented rack assembly 110 are configured to adjustablyengage and securely close the sports footwear 80 about a user.

The lever assembly 90 may be any conventional lever assembly as areknown in the art. For example, a suitable lever assembly may beconstructed based on the lever assemblies disclosed in any of U.S. Pat.No. 8,096,065, to Marechal, U.S. Pat. No. 7,603,795, to Pallatin, and/orU.S. Pat. No. 5,983,531, to Chaigne et al., all of which areincorporated by reference above. The lever assembly 90 shown in FIG. 1includes a mounting plate 91 that may be configured for attachment to aboot or binding by any suitable means, for example, by stitching,rivets, adhesives, a strap, or the like. A lever arm 92 is pivotablyattached to the mounting plate 91 with a first pivot pin 93 that extendsthrough a mounting plate wing or boss 94. A rod assembly 95 is attachedto the lever arm 92 at an intermediate location with a second pivot pin96, and is attached near one end to a hook or latching element 97 with athird pivot pin 98. In an exemplary embodiment, the length of the rodassembly 95 is adjustable, for example, with a threadable attachment orthe like. The latching element 97 includes a rung, hook, or othertransverse elements 99 that is configured to engage the segmented rackassembly 110 at a selectable location on the rack assembly 110. To closethe fastening system 100, the transverse element 99 is positioned toengage a selected tooth 122 of the rack assembly 110, and the lever arm92 is pivoted about the first pivot pin 93 to a latching position(counterclockwise in FIG. 1).

The articulated segmented rack assembly 110 comprises a flexible cable112, for example, a steel or composite cable, that may include a sheath114 over a portion of the cable 112. A plurality of rack segments 120(three shown) clamp onto and are fixed to the cable 112.

In this embodiment, the rack segments 120 each include a toothed member124 and an attachment plate 126. The toothed member 124 includes one ormore hook elements or teeth 122 (two shown for each rack element 120)that are configured to engage the transverse element 99 of the leverassembly 90. The toothed member 124 and the plate 126 are assembled tofix the rack segments 120 to the cable 112.

FIG. 2 shows an exploded view of the segmented rack assembly 110, FIG. 3shows a bottom view of the rack assembly 110, and FIG. 4 shows across-sectional view of the rack assembly 110 through section 4-4 inFIG. 3.

Each toothed member 124 includes a pair of generally parallel,longitudinal channels 125 that extend along the length of the toothedmember 124 and are sized to engage the cable 112. The attachment plates126 similarly include a pair of longitudinal channels 127 that arealigned with the toothed member channels 125 when the rack assembly 110is assembled.

A fastener 128 attaches each attachment plate 126 to a correspondingtoothed member 124 to clamp the rack segment 120 onto the cable 112,such that cable portions 112A, 112B are retained in and between thechannels 125, 127. In the current embodiment, the fasteners 128 arescrews, but may alternatively comprise bolts, rivets, or the like.

The cable 112 in this embodiment includes two cable portions 112A, 112Bthat are joined together at their distal ends with a U-shaped crimpconnector 116. Alternatively, but not preferably, the cable 112 maysimply loop around to engage the parallel channels 125, 127 in the racksegment 120. The distal-end rack segment 120 may optionally define atransverse channel (not shown) that joins the parallel longitudinalchannels 125, 127 and receives a looped portion of the cable 112.

As seen most clearly in FIGS. 1 and 2, in this embodiment, the racksegments 120 are attached to the cable 112 with a small gap betweenadjacent rack segments 120, and the ends of the rack segments 120 areshaped to permit neighboring rack segments 120 to move angularly withrespect to each other through flexure of the cable 112. The cable 112therefore defines a hinge connecting adjacent rack segments 120.Therefore, the rack segments 120 may articulate relative to each other,such that the rack assembly 110 can conform to the shape of the boot 80.

It is contemplated that the present invention may be practiced with moreor fewer rack segments 120 to meet the needs of a particularapplication.

The rack segments 120 may be formed from any suitable material. Forexample, in a current embodiment, the toothed member 124 and theattachment plate 126 are formed from aluminum. However, it iscontemplated that these components may be formed from other materials,for example, rigid plastics or composite materials.

To use the fastener system 100, typically the lever assembly 90 isfixedly attached to a boot 80, or mounted on a strap to engage the boot80, for example. The cable 112 supporting the rack assembly 110 is fixedon an opposite side of the boot 80. The user may position the rackassembly 110 in a desired location to engage the lever assemblytransverse element 99, with the lever arm 92 pivoted towards an openposition. The transverse element 99 engages the selected tooth 122 ofone rack segment 120, and the lever arm 92 is then pivoted to anover-center closed position.

A side view of another embodiment of a rack assembly 210 in accordancewith the present invention is shown in FIG. 5. The rack assembly 210 inthis embodiment comprises a plurality of segments including proximalrack segments 220 and a distal rack segment 220′. The rack segments 220,220′ are formed unitarily, that is, each as a single member, and areattached to the cable 112 (shown in phantom) by crimping.

The rack segments 220, 220′ each include a plurality of hook portions orteeth 222 that are shaped to engage the lever assembly 90 describedabove, and a base portion 226, 226′. A first end 221 of each segment220, 220′ is convexly curved, for example, forming a partiallycylindrical face, and a second end 223 of the proximal rack segments 220is concavely curved and shaped to receive the first end 221 of theneighboring segment 220 or 220′.

Refer also to FIG. 6, which shows a perspective view of the proximalrack segment 220. In this embodiment, the teeth 222 are narrower inwidth than the base portion 226 and approximately centered such thatlateral end portions 229 are defined on either side of the teeth 222.The proximal rack segment 220 further includes a pair of longitudinalchannels 225 that are sized to receive and engage the cable 112. In thecurrent embodiment, the channels 225 include one or more grippingtransverse teeth or gripping elements 127 (five shown). The longitudinalchannels 225 each include a narrow inwardly-extending portion 228. Theproximal rack segment 220 is formed from a plastically deformablematerial, for example, aluminum, or a deformable polymeric material.

A perspective view of the distal rack segment 220′ is shown in FIG. 7.The distal rack segment 220′ is generally similar to the proximal racksegments 220, except as discussed herein, with side channels 225′configured to receive and crimp to the cable 112. From FIG. 5, it isclear that the distal rack segment 220′ second end 223′ does not have aneighboring rack segment. Rather, the distal rack segment 220′ secondend 223′ includes a transverse channel or recess 224′ that serves as aguide or retainer for the U-shaped crimp connector 116 or end portion ofthe cable 112.

In this embodiment, the rack segments 220, 220′ are clamped to the cable112 by positioning cable 112 at the desired position to engage thelongitudinal channels 225, 225′ and crimping the rack segments 220,220′, for example, by compressing the end portions 229, such that thegripping elements 227 engage and secure the flexible cable 112. It willbe appreciated that the crimping is facilitated by the inner narrowportion 228 of the longitudinal channels 225.

A lower side perspective view of another embodiment of a rack assembly310 in accordance with the present invention is shown in FIG. 8. Therack assembly 310 in this embodiment also comprises a plurality ofproximal rack segments 320 and a distal rack segment 320′. Two proximalrack segments 320 are shown in FIG. 8, although more or fewer proximalrack segments may be included.

In this embodiment, the proximal rack segments 320 include a toothedmember 324 with a plurality of teeth 322, and an attachment plate 326that is fixed to a bottom of the corresponding toothed member 324 tolock the rack segment 320 to the flexible cable 112. Similarly, thedistal rack segment 320′ includes a toothed member 324′ and anattachment plate 326′ that is fixed to a bottom of the toothed member324′ to attach the distal rack segment 320′ to the flexible cable 112.The front and back faces of the rack segments 320 and the back face ofthe distal rack segment 320′ are shaped to permit pivotal motion betweenneighboring rack segments 320, 320′ by flexure of the cable 112.

FIG. 9 shows an exploded view of the proximal rack segment 320 with thecable 112 shown in phantom. The toothed member 324 includes a bottomportion (i.e., a face opposite the teeth 322) defining two parallellongitudinal channels 325. In this embodiment, the channels 325 have adepth that is approximately equal to, or slightly less than, thediameter of the cable 112, such that the received portion of the cable112 substantially fits within the longitudinal channel 325. Thelongitudinal channels 325 optionally include a plurality of ridges orgripping elements 337 extending inwardly from the channels 325. A recess330 is defined on the bottom portion of the proximal rack segment 320between the longitudinal channels 325, and is sized to receive theattachment plate 326.

The bottom portion of the proximal rack segment 320 further defines aplastically deformable rivet portion 332 extending distally from therecess 330. In this embodiment, the rivet portion 332 is round andtubular in shape, although other shapes may alternatively be used. Theattachment plate 326 includes an aperture 327 that is sized andpositioned to slidably engage the rivet portion 332 when the attachmentplate 326 is received into the recess 330.

It will now be appreciated that the proximal rack segment 320 isattached to the cable 112 by positioning the cable 112 at a desiredposition in the parallel longitudinal channels 325, pressing theattachment plate 326 into the recess 330 such that the segment 320clamps onto the cable 112, and deforming the tubular rivet portion 332to lock the attachment plate 326 to the toothed member 324.

FIG. 10 shows an exploded view of the distal rack segment 320′, which issubstantially similar to the proximal rack segments 320 in mostrespects. The distal rack segment 320′ includes a toothed member 324′with a plurality of teeth 322 (two shown), and a U-shaped channel 325′that is sized and configured to receive the flexible cable 112. A rivetportion 332 extends from a recess 330′ on the bottom of the toothedmember 324′. An attachment plate 326′ with an aperture 327 is sized andconfigured to be positioned in the recess 330 to clamp onto the cable112, and the rivet portion 332 is plastically deformed to lock theattachment plate 326′ to the toothed portion 324′, and thereby fix thedistal rack segment 320′ to the cable 112.

While illustrative embodiments have been illustrated and described, itwill be appreciated that various changes can be made therein withoutdeparting from the spirit and scope of the invention.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A fastener assembly forsports footwear comprising: a lever assembly having a lever arm movablebetween an open position and a closed position, and a hooking member;and a segmented rack assembly comprising a flexible cable having firstand second spaced-apart portions, and a plurality of rack segments thatare fixed to the cable first and second portions, each rack segmenthaving a plurality of teeth, wherein the teeth are sized and shaped toreleasably engage the hooking member; wherein the plurality of racksegments are fixed serially on the cable such that adjacent racksegments are hingedly joined by the cable.
 2. The fastener assembly ofclaim 1, wherein the rack segments each comprise a toothed memberdefining a plurality of teeth that are configured to selectively engagethe hooking member and an attachment plate that is attached to thetoothed member to fixedly attach the rack segment to the flexible cable.3. The fastener assembly of claim 2, wherein at least one of the toothedmember and the attachment plate define a pair of spaced-apart channelsthat are configured to engage the flexible cable.
 4. The fastenerassembly of claim 3, wherein the attachment plate is attached to thetoothed member with a threaded member that extends through an aperturein the attachment plate and threadably engages the toothed member. 5.The fastener assembly of claim 3, wherein the toothed member furthercomprises a rivet portion that extends distally from the toothed member,and the attachment plate further comprises an aperture sized andconfigured to slidably receive the rivet portion, wherein the rivetportions fix the attachment plate to the toothed member.
 6. The fastenerassembly of claim 1, wherein each of the plurality of rack segments isunitarily formed and comprise a toothed portion and a base portion,wherein the base portion comprises a crimpable channel portion that issized and configured to receive the cable and to fix the rack segment tothe flexible cable by crimping the crimpable channel portion.
 7. Thefastener assembly of claim 6, wherein the crimpable channel portionfurther comprises a narrow inner channel portion that facilitatescrimping the channel portion.
 8. The fastener assembly of claim 6,wherein the crimpable channel portion further comprises a plurality ofgripping elements that engage the flexible cable.
 9. The fastenerassembly of claim 1, wherein the flexible cable further comprises aU-shaped crimp connector that connects two portions of the flexiblecable.
 10. The fastener assembly of claim 9, wherein the plurality ofrack segments includes a distal rack segment having a distal channelportion that is configured to receive the U-shaped crimp connector. 11.The fastener assembly of claim 1, wherein the plurality of rack segmentsis fixed to the cable such that adjacent rack segments are separated bya gap.
 12. The fastener assembly of claim 1, wherein at least one of theplurality of rack segments defines a convex end portion, and at leastone of the plurality of rack segments defines a concave end portion thatis sized and shaped to receive the convex end portion.
 13. The fastenerassembly of claim 12, wherein the convex end portion is cylindrical. 14.The fastener assembly of claim 1, wherein the segmented rack assemblycomprises at least three rack segments.
 15. The fastener assembly ofclaim 1, wherein the toothed members are formed of aluminum.
 16. Asegmented rack assembly for a sporting boot fastener assemblycomprising: a flexible cable having first and second spaced-apartportions; and at least three rack segments, wherein each rack segment isfixed to the cable first and second portions, each rack segment having aplurality of spaced-apart teeth that are sized and configured toreleasably engage a hook member; wherein the at least three racksegments are fixed to the flexible cable such that adjacent racksegments are hingedly connect by the cable.
 17. The segmented rackassembly of claim 16, wherein the at least three rack segments eachcomprise a toothed portion and an attachment plate, and wherein eachrack assembly is attached to the flexible cable by clamping the flexiblecable between the toothed portion and the attachment plate.